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Hydro-Control V User Guide: Hydronix Part No: HD0193 Revision Date: March 2010
Hydro-Control V User Guide: Hydronix Part No: HD0193 Revision Date: March 2010
User Guide
1
COPYRIGHT
Neither the whole or any part of the information contained in nor the product described in this documentation
may be adapted or reproduced in any material form except with the prior written approval of Hydronix
Limited, hereinafter referred to as Hydronix.
CUSTOMER RESPONSIBILITY
The customer in applying the product described in this documentation accepts that the product is a
programmable electronic system which is inherently complex and which may not be completely free of
errors. In doing so the customer therefore undertakes responsibility to ensure that the product is properly
installed commissioned operated and maintained by competent and suitably trained persons and in
accordance with any instructions or safety precautions made available or good engineering practice and to
thoroughly verify the use of the product in the particular application.
ERRORS IN DOCUMENTATION
The product described in this documentation is subject to continuous development and improvement. All
information of a technical nature and particulars of the product and its use including the information and
particulars contained in this documentation are given by Hydronix in good faith.
Hydronix welcomes comments and suggestions relating to the product and this documentation.
This documentation is intended only to assist the reader in the use of the product and therefore Hydronix
shall not be liable for any loss or damage howsoever arising from the use of information or particulars in or
any error in or omission from this documentation.
ACKNOWLEDGEMENTS
Hydronix, Hydro-Probe, Hydro-Skid, Hydro-Mix, Hydro-View and Hydro-Control are Registered Trade Marks
of Hydronix Limited.
Hydro-Control V is an easy to use control system for controlling water addition during concrete mixing. In
conjunction with the Hydronix Hydro-Mix V/VI or Hydro-Probe Orbiter it is designed to precisely achieve the
required moisture target without the need for metering the water, although use of a water meter is preferred.
From software version HS0035 v. 4.20, the Hydro-Control V has temperature compensation which enables
the control of water addition to achieve the required consistency throughout the year, regardless of variation
in material temperature.
It is simple to install and can be fitted to both new and existing plants. It uses the latest Hitachi H8
microprocessor with SMD technology to achieve a compact and reliable unit.
The unit contains sophisticated control software to ensure the user can achieve the desired result with the
minimum fuss.
The large, clear display ensures the principal information is readily visible without confusion. Via a few easily
accessed menus, the user can define the mix cycle and the recipes as well as monitor the mixing cycle
status, recipe information, sensor signal trend information and system diagnostics.
The Hydro-Control V can be connected to a batch controller via an RS232 serial link to allow transfer of mix
cycle information and remote recipe selection. The RS232 port is also used to send software upgrades from
a service computer.
The aim of this User Guide is to provide a simple operational overview follow by a more detailed screen-by-
screen explanation of the system operation.
Pre Wet
First Mix
Time
Mixer
Loading
Time
First Mix
Time
Mixer
Loading
Time
The Hydro-Control V can operate in one of three control modes. The control mode to be used is defined by
the recipe and may be different for each recipe.
Preset Mode
A fixed amount of water defined by the recipe is added during both the pre-wet (if required) and final-wet
phases of the mix cycle regardless of the current moisture reading, this mode can also be operated without a
sensor being connected.
Auto Mode
An amount of water defined by the recipe is added during the pre-wet phase (if required) and the sensor
moisture reading is used to control the water addition up to a target defined by the selected recipe during the
final-wet phase of the mix.
Calc Mode
An amount of water is added during the pre-wet (if required) and then the system calculates the amount of
water to add during the final-wet phase from a ‘Calculated Moisture Target’ and recipe Dry weight parameter.
NOTE: This mode requires a Calib mode (calibration) cycle to be completed before a Calc Mode cycle
can be made. This mode will be disabled if no value of ‘Dry weight’ has been entered or if there is no
water meter present.
The First mix time needs to be sufficiently long to allow the ‘dry’ aggregates, the cement and any pre-wet (if
selected) to mix so that a reasonable reading for the average moisture content can be obtained. Similarly the
Final mix time needs to be long enough to allow Final wet to mix with the aggregates and cement so that a
good consistency and reasonable reading for the average moisture content is obtained. Both these times
may be established by observing the moisture trend on the Hydro-Control V during a mix cycle. Sufficient
mixing has occurred when the moisture trend shows reasonable stability (i.e. a flat line) before the Final wet
and MIX COMPLETE phases are reached respectively.
During the mix phases of a Calc or Calib mode cycle the system averages the moisture values over the last
Averaging time seconds (defined by the system parameter Averaging time - see section Edit Control
Parameters) of the mix time.
Therefore, in Calc or Calib mode, during the First mix and Final mix phases the system will mix for at least
the amount of time defined by the Averaging time, e.g. if the First mix time parameter is set to 10 seconds
and the Averaging time is set to 20 seconds the first mix will last for 20 seconds, however, if the First mix
time is set to 25 seconds and the Averaging time is set to 20 seconds the first mix will last for 25 seconds.
As it is critical that reasonable stability has been reached before averaging starts it is recommended
that the First mix time and the Wet mix time parameters be set to be at least twice as long as the
Averaging time.
Mixer Type Control Mode Averaging Time First Mix Wet Mix
(s) Time (s) Time (s)
Single Star Planetary Auto N/A 30 50
Calc 20 50 50
Two Star Planetary Auto N/A 15 20
Calc 15 40 40
Twin Shaft Auto N/A 15 20
Calc 15 40 40
Ribbon Auto N/A 30 60
Calc 20 50 60
Turbo Auto N/A 20 30
Calc 15 40 50
Mix times for Pre-set mode should be the same as for the intended Control Mode
The above is intended only as a guide for getting started. Actual mixing times will vary, and should be
optimised for each application.
Up to 99 recipes are available. The number of recipes displayed is selectable (see section ‘Edit System
Parameters’. Initially all the parameters of the recipes will be set to their default values (see section Edit
recipe parameters).
To select a recipe from the list use and to move the cursor to the required recipe or
Select the parameters to be changed by using the and keys, and then typing in the
desired value.
Enter the digits, ignoring the decimal point – although with preceding zero if necessary. Alternatively, values
can be increased or decreased by using the <Inc> (F1) and <Dec> (F2) keys - these are also used for non-
numerical items which cycle through the valid entries in turn.
After completion of editing press <Back> (F5) and then either of the following keys:
to cancel and return to the Recipe Menu. Choosing this option will return any edited
X parameters to their original values.
Scrolling down to the ‘More…’ statement at the bottom of the list will display the second page of the Edit
Recipe Screen.
Alternatively, the control mode of the current recipe may be changed from the Start Menu by pressing
<Mode> (F3). The Hydro-Control V will cycle through the control modes available with successive presses of
<Mode> (F3).
NOTE: Until the recipe’s Dry Weight parameter has been defined for the recipe the only control modes
available will be Pre-set and Auto.Once a dry weight is defined, the Calib mode will be available and after a
calibration cycle has been completed the Calc mode will also become available.
Mixer
Loading Add Discharge
Cement
Time
3. Enter the amount of pre-wet water required in Pre-wet water parameter. If you do not require any
pre-wet set the Pre-wet water and Pre-wet target parameters to zero.
4. Enter the amount of final (main) water required in Preset Final parameter.
5. Check that the First mix time and Final mix time parameters are correct.
6. Check the Water limit parameter on page two of the recipe is correct
7. Press <Back> (F5) and then 9 to save the changed values and return to the Recipe Menu.
9. Press <Mode> (F3) until Preset is displayed under the Recipe number
10. Start the mix cycle from the batch controller or manually by pressing Start <F1>
<Resume> (F1) Continues the cycle from the point where it was paused.
<Abort> (F2) Allows the current mix to be aborted. When pressed the option to generate MIX
COMPLETE signal is prompted with the following “Mix Complete Required?”,
<Yes> (F2) and <No> (F3). If ‘No’ is selected it will return to the Start Menu. If
‘Yes’ is selected the mix complete signal is generated and <Reset> (F2) returns to
the Start Menu and clears the MIX COMPLETE signal.
<Trim> (F3) Opens the Fine Water valve all the time the key is depressed, allowing manual
adjustment of the moisture level.
<Update> (F5) Followed by 9 saves the adjusted water amounts and moisture level to the
current recipe.
Pressing <Update> (F5) during Pre-wet or First mix time phases of the mix cycle
updates the Pre-wet water and Pre-wet target parameters.
Pressing <Update> (F5) during Final wet or Final mix time phases of the mix
cycle updates the Preset Final and the Target moisture parameters.
At the end of the Final mix time a MIX COMPLETE signal is generated indicating to the batch control
system that the mixer is ready for discharging. If discharge is set to manual and an automatic Reset is not
received then the following options will be displayed:
<Reset> (F2) Returns the unit to standby and clears the MIX COMPLETE signal.
<Trim> (F3) Opens the Fine Water valve all the time the key is depressed, allowing manual
adjustment of the moisture level.
<Update> (F5) Followed by 9 saves the adjusted water amounts and moisture levels to the
current recipe.
Preset Final and Target moisture parameters are updated.
Moisture
target
Mixer
Loading Add Discharge
Cement
Time
It is usual to run the mix cycle in Preset mode for several cycles, switching to Auto mode to establish mixing
time, water quantities and to ensure that good mix-to-mix moisture consistency is achieved. The mix-to-mix
consistency can be checked by pressing <More…> (F5) and then <Log> (F2) where Final % values can be
inspected.
It is suggested that the ‘discharge’ is set to manual mode during Auto mode setup to prevent automatic
discharge; this enables manual correction to the mix after MIX COMPLETE
3. Enter the amount of pre-wet water required in Pre-wet water parameter. If you do not require any
pre-wet set the Pre-wet water and Pre-wet target parameters to zero.
4. Enter the amount of final (main) water required in Preset Final parameter, if you are unsure, enter a
value lower than that required. A manual adjustment to a ‘good mix’ can be performed during the
mix cycle.
5. Check that the First mix time and Final mix time parameters are correct.
6. Check the Water limit parameter on page two of the recipe is correct
7. Press <Back> (F5) and then 9 to save the changed values and return to the Select Recipe
menu.
9. Press <Mode> (F3) until Preset is displayed under the Recipe number
10. Start the mix cycle from the batch controller or manually by pressing Start <F1>
12. Observe the mix consistency or the quantity of water added and manually add water using <Trim>
(F3) until the desired amount of water for the Final-wet phase has been added.
If a water meter is fitted the quantity of water added will be displayed under the tap icons.
13. When the correct amount of water has been added press <Update> (F4).
16. At the end of the Final mix time a MIX COMPLETE signal is issued. After the mixer is discharged
press <Reset> (F2) to return to the Start Menu
17. Press <Mode> (F3) until Auto is displayed under the recipe number. The recipe is now ready to run
in Auto mode.
<Resume> (F1) Continues the cycle from the point where it was paused.
<Abort> (F2) Allows the current mix to be aborted. When pressed the option to generate MIX
COMPLETE signal is prompted with the following “Mix Complete Required?”,
<Yes> (F2) and <No> (F3). If ‘No’ is selected it will return to the Start Menu. If
‘Yes’ is selected the mix complete signal is generated and <Reset> (F2) returns to
the Start Menu and clears the MIX COMPLETE signal.
<Trim> (F3) Opens the FINE WATER valve all the time the key is depressed, allowing manual
adjustment of the moisture level.
<Update> (F5) Followed by 9 saves the adjusted water amounts and moisture levels to the
current recipe.
Pressing <Update> (F5) during Pre-wet or First mix time phases of the mix cycle
updates the Pre-wet water and Pre-wet target parameters.
Pressing <Update> (F5) during Final wet or Final mix time phases of the mix
cycle updates the Preset Final and the Target moisture parameters.
At the end of the Final mix time a MIX COMPLETE signal is generated, indicating to the batch control
system that the mixer is ready for discharging. If discharge is set to manual and an automatic Reset is not
received then the following options will be displayed:
<Reset> (F2) Returns the unit to standby and clears the MIX COMPLETE signal.
<Trim> (F3) Opens the FINE WATER valve all the time the key is depressed, allowing manual
adjustment of the moisture level.
<Update> (F5) Followed by 9 saves the adjusted water amounts and moisture levels to the
current recipe.
Preset Final and Target moisture parameters are updated.
From the Start Menu, pressing <More…> (F5), followed by <Setup> (F1) gives access to the system
configuration menus. It is necessary to enter the Advanced Password (see Appendix D) to access the
Control Parameters, after the password has been entered press <Control> (F3).
The following parameters are used to control the progressive water addition: -
Gain: Controls how fast water is put into the mixer. A higher value will increase the rate at which water
enters the mixer. It is normal to start with a value of 20. Observe the trend line during a mix cycle to
determine if the water is entering the mixer at the desired rate. Increase the value (initially by 5) to increase
the water flow rate, reduce the value to reduce the water flow rate. A value of 20-40 is typical for moderate
to good mixers with correctly sized water valves. Slower acting mixers will use lower values.
Upper Control Threshold: Controls the point when the water valves change from ‘always on’ to ‘pulsing’.
A lower value will keep the valves in the ‘always on’ state for longer, only allowing the valves to ‘pulse’ on
and off closer to the Moisture target. Values of 50 or 70 are typical for most applications if the Gain is set
correctly.
Lower Control Threshold: Determines the minimum flow rate that can be used by the progressive
algorithm. This parameter is used to prevent the water flow being too slow when the actual moisture is very
close to the Moisture Target. Typical values will be between 10 and 25. A higher value increases the
minimum water flow near the Moisture Target.
Valve on/off Time: Determines how quickly the valve can be switched on and then immediately off again.
This parameter should be set as fast as practically possible for a pulse of water to be delivered. Once set
this parameter should not be altered.
Optimising the Auto mode control is a balance between the top three parameters. It is suggested that
starting from default values, the parameters are altered in the following sequence:
1. Set the Gain parameter to achieve reasonable flow at the beginning of the Final wet phase
2. Increase the Lower Control Threshold so that the Moisture Target is reached at the maximum
possible rate without excessive overshooting.
3. Set the Upper Control Threshold to optimise when the valves switch from ’always on’ to ‘pulsing’
NOTE: Setting up the Auto mode control parameters should be performed with a full batch. The Recipe
gain parameter in the relevant recipe should be set to the batch size if a smaller batch is to be made.
Moisture
target
moisture
Time
Valve
off always on pulsing off
output
The advantage of Calc mode is that the water is added in ‘one shot’, which usually makes the Final wet
phase quicker than would be the case with progressive water addition. Fine Delivery determines the
amount of water to be added with the fine valve only, so that the calculated value of water is delivered
accurately and without causing excessive overshoot.
Moisture
target
‘Dry’ reading
used to
calculate
Final water
Averaging Averaging
time time
Mixer
Loading Add Discharge
Cement
Time
Calibrating a Recipe
In order to run a recipe in Calc mode the recipe needs to be calibrated.
It is usual to run the mix cycle in Preset mode for several cycles before performing a calibration to establish
mixing time, water quantities and to ensure that good mix-to-mix moisture consistency is achieved. The mix-
to-mix consistency can be checked by pressing <More…> (F5) and then <Log> (F2) where Final % values
can be inspected.
It is suggested that the ‘discharge’ is set to manual mode during calibration to prevent automatic discharge;
this enables manual correction to the mix after MIX COMPLETE.
A calibration run can be carried out in two ways depending on whether any ‘admix’ is required.
When calibrating without admix, or when the admix is added during the First mix time, there is usually one
water addition phase and the mix cycle will complete with one final-wet and one wet-mix phase. The final
mix time used during a calibration cycle is extended by the Mix extension time to ensure that a good final
reading is obtained.
3. Enter the amount of pre-wet water required in Pre-wet water parameter. If you do not require any
pre-wet, set the Pre-wet water and Pre-wet target parameters to zero.
4. Enter the amount of final (main) water required in Preset Final parameter, if you are unsure, enter a
value lower than that required. A manual adjustment to a ‘good mix’ can be performed at the end of
the mix cycle, so ensure that the discharge is set to manual.
5. Check that the First mix time and Final mix time parameters are correct.
6. Set the Dry weight parameter on page two of the recipe to that of your mix.
7. Check the Water limit parameter on page two of the recipe is correct
8. Press <Back> (F5) and then 9 to save the changed values and return to the Recipe Menu.
10. Press <Mode> (F3) until Calib is displayed under the Recipe number
11. Start the mix cycle from the batch controller or manually by pressing <Start> (F1)
12. On starting the mix an edit box appears which shows the current calibration water (this will be the
amount entered in the parameter Preset Final Water. Type in the amount of water required if this is
different and then press to accept.
9
13. At the end of the Final mix time a MIX COMPLETE signal is issued. An edit box will appear which
shows the final moisture reached for this mix. You may accept this as the Moisture target or enter a
new value if appropriate.
NOTE: Entering a new value of moisture only alters the displayed moisture figure - the calibration is
not effected. Then press the accept button . 9
14. If the discharge is set to manual, then the quantity of water may be manually adjusted by pressing
<Trim> (F3). The quantity of water added will be displayed under the tap icons.
15. When the correct amount of water has been added press <Update> (F4), followed by 9
16. Discharge the mixer and press <Reset> (F2) to return to the Start menu
The recipe is now calibrated and Calc will be displayed under the recipe number indicating that the next mix
cycle will be performed in Calc mode.
4. Scroll to the bottom of the recipe menu to the parameter Calibration Type and select 2 point
5. Enter the amount of pre-wet water required in Pre-wet water parameter. If you do not require any
pre-wet set the Pre-wet water and Pre-wet target parameters to zero.
6. Enter the amount of final (main) water required in Preset Final parameter, if you are unsure, enter a
value lower than that required. A manual adjustment to a ‘good mix’ can be performed at the end of
the mix cycle, so ensure that the discharge is set to manual.
7. Check that the First mix time and Final mix time parameters are correct.
8. Set the Dry weight parameter on page two of the recipe to that of your mix.
9. Check the Water limit parameter on page two of the recipe is correct
10. Press <Back> (F5) and then 9 to save the changed values and return to the Recipe Menu.
12. Press <Mode> (F3) until Calib is displayed under the Recipe number
13. Start the mix cycle from the batch controller or manually by pressing <Start> (F1)
14. On starting the mix an edit box appears which shows the current calibration water (this will be the
amount entered in the parameter Calib Water in the first and the Preset Final – Calib Water in the
second (if this is greater than zero). Type in the amount of water required if this is different and then
press to accept the first and to accept the second value.
9 9
15. At the end of the Final mix time a MIX COMPLETE signal is issued. An edit box will appear which
shows the final moisture reached for this mix. You may accept this as the Moisture target or enter a
new value if appropriate.
NOTE: Entering a new value of moisture only alters the displayed moisture figure - the calibration is
not effected. Then press the accept button
9 .
16. If the discharge is set to manual, then the quantity of water may be manually adjusted by pressing
<Trim> (F3). The quantity of water added will be displayed under the tap icons.
17. When the correct amount of water has been added press <Update>F4), followed by 9
18. Discharge the mixer and press <Reset> (F2) to return to the Start menu
The recipe is now calibrated and Calc will be displayed under the recipe number indicating that the next mix
cycle will be performed in Calc mode
<Resume> (F1) Continues the cycle from the point where it was paused.
<Abort> (F2) Allows the current mix to be aborted. When pressed the option to generate MIX
COMPLETE signal is prompted with the following “Mix Complete Required?”,
<Yes> (F2) and <No> (F3). If ‘No’ is selected it will return to the Start Menu. If
‘Yes’ is selected the mix complete signal is generated and <Reset> (F2) returns to
the Start Menu and clears the MIX COMPLETE signal.
At the end of the Final mix time a MIX COMPLETE signal is generated indicating to the batch control
system that the mixer is ready for discharging. If discharge is set to manual and an automatic Reset is not
received then the following options will be displayed:
<Reset> (F2) Returns the unit to standby and clears the MIX COMPLETE signal.
<Trim> (F3) Opens the Fine Water valve all the time the key is depressed, allowing manual
trimming of the moisture level.
<Update> (F5) Followed by 9 saves the adjusted water amounts and moisture levels to the
current recipe.
Preset Final and Target moisture parameters are updated.
A Calc mode mix cycle may be paused at any phase of the mix cycle by pressing <Pause> (F2).
<Resume> (F1) Continues the cycle from the point where it was paused.
<Abort> (F2) Allows the current mix to be aborted. When pressed the option to generate MIX
COMPLETE signal is prompted with the following “Mix Complete Required?”,
<Yes> (F2) and <No> (F3). If ‘No’ is selected it will return to the Start Menu. If
‘Yes’ is selected the mix complete signal is generated and <Reset> (F2) returns to
the Start Menu and clears the MIX COMPLETE signal.
At the end of the Final mix time a MIX COMPLETE signal is generated indicating to the batch control
system that the mixer is ready for discharging. If discharge is set to manual and an automatic Reset is not
received then the following options will be displayed:
<Reset> (F2) Returns the unit to standby and clears the MIX COMPLETE signal.
NOTE: <Update> is not available in Calc mode; any adjustment should be performed using the Water trim
parameter.
When Calc mode is the current the control mode <Trim> (F4) will be displayed in the Start Menu.
When <Trim> (F4) is pressed an edit box appears allowing an amount of water to be added or removed from
all subsequent Calc mode mix cycles for the current recipe.
The numeric keys and <Inc> (F1), <Dec> (F2) and <+/-> (F3) may be used to set the value of adjusted
water. Alternatively the Water trim parameter can be edited using the Edit recipe menu.
NOTE: The Minus tolerance moisture alarm will be disabled if a negative adjustment is entered to prevent
nuisance alarms.
The Hydro-Control V can operate in one of two Pre-wet mix cycle modes:
The speed and accuracy of the Pre-wet water addition will be determined by the valves and the In-flight and
Fine delivery settings in the Edit Control menu.
Auto mode control parameters that are optimised for final water addition where accuracy is required may
produce a slower than desirable Pre-wet where accuracy is not normally as important. In the case where an
Auto mode Pre-wet is followed by a Calc mode Final wet the Recipe gain can be increased to improve the
speed of the Pre-wet water addition.
Temperature Compensation
Temperature compensation can be used to correct for changes in ambient temperatures throughout the year
and adjust the final moisture target to maintain mix consistencies. Two recipe parameters are used for
temperature compensation:
Temperature : The is the base temperature from which the compensation will be calculated.
The temperature is measured by the sensor and displayed on the front page (see Figure 9).
At the time of setting up the recipe this value should be read from the front screen and the
reading used in the recipe as the base temperature. This value should not be adjusted
following this reading.
Temp. Coeff : The temperature coefficient is the compensation factor in %moisture / Temperature
(i.e.: how far the moisture target is anticipated to change per degree change in temperature)
From these two parameters the Moisture Target is then calculated by the following:
Correction is applied for ‘Calc’ or ‘Auto’ mixes only, there is no compensation during a Calib mix or if a Pre-
set amount of water is added.
Example:
Final Moisture 6.5 %
o
Temperature 20 C
Temp. Coeff. 0.100 %moisture/ oC
If the current temperature measured is 25.0 oC then the moisture target will become 7.0%.
If the current temperature measured is 15.0 oC then the moisture target will become 6.0%.
Menu Tree
Start Menu
Edit
Recipe
Edit Edit
Diagnostics Test
System Control
Resonator
Display
Monitor
Input
Sensor
Configuration
Output
Keys
In routine operation the user can operate the system using only the two highlighted menus shown above
(‘Mix Cycle’ & ‘Select Recipe’). However additional ‘Set up’ and ‘Diagnostic’ menus are provided to permit
flexibility and complete control.
Rom OK
perform Ram test?
is displayed for 5 seconds. Pressing will start the RAM test, which takes approximately 60
seconds. 9
After the Ram test completes or 5 seconds has passed, the Hydronix logo and firmware version is shown
and is then replaced by the Start menu and ‘trend’ moisture graph.
• The ‘trend’ display is a scrolling moisture level graph, which also shows the ‘Target’ (T) and ‘Alarm’ (A)
levels for the chosen Recipe if in ‘Auto’ or ‘Calculation’ modes.
•
…
‘Tap’ icons, which show the Status (Off or On …….
….. ) of the FINE WATER and COARSE WATER
valves. Underneath the valves are number(s) showing how much water has been delivered. If a water
meter is used the total number of litres or gallons is shown. If no water meter is used, beneath each
valve is the time that valve has been open, in units of 0.1 seconds.
• Recipe number, batch number and control method (top right of display).
• Moisture readings and targets (centre right of display). Large number shows current moisture, smaller
numbers underneath show:
• The amount of water to be added during the current phase of the mix cycle
• Moisture target of the current recipe
• Trim water of the current recipe (only in Calc mode)
• The temperature of the mixture (in degrees Centigrade or Fahrenheit) is also shown at the top right of
the display, just above the moisture axis of the trend graph.
<Recipe> (F2) Displays the Select Recipe menu where recipes may be selected and edited.
<Setup> (F1) Displays the Setup System menu (see section Setup System).
<Log> (F2) Displays the Mix log (see section Mix log).
<Back> (F5) Returns to the main menu with <Start> (F1), <Recipe> (F2), <Mode> (F3)
and <More…> (F5) present
When Calc mode is the current the control mode <Trim> (F4) will also be displayed below the moisture
reading on the main page.
<Trim> (F4) An edit box allows trim water to be added or removed from all subsequent
calculation runs for the current recipe.
The numeric keys and <Inc> (F1), <Dec> (F2) and <+/-> (F3) may be used to set
the value of trim water.
Alternatively the trim parameter can be edited using the Edit recipe menu.
The system is set up with 99 recipes. Initially all the parameters of these recipes will be set to their default
values (see section Edit recipe parameters).
To select a recipe from the list use and to move the cursor to the required recipe or
<Defs> (F1) Set the selected recipe to the values defined by the Default Recipe – see section
Edit System Parameters.
Enter the digits ignoring the decimal point – although with preceding zero if necessary. Alternatively, values
can be increased or decreased by using the <Inc> (F1) and <Dec> (F2) keys - these are also used for non-
numerical items which cycle through the valid entries in turn.
• Use the and keys to move the cursor to the Final mix time parameter
After completion of editing press <Back> (F5) and then either of the following keys:
9 to save the changed values and return to the Select Recipe menu.
to cancel and return to the Select Recipe menu. Choosing this option will return any edited
X parameters to their original values.
Scrolling down to the ‘More…’ statement at the bottom of the list will display the second page of the Edit
Recipe menu.
Pre-wet target: The moisture value to be reached during the Pre-wet phase of the mix cycle if the Pre-wet
mode is set to Auto mode
Pre-wet mode: The Hydro-Control V can operate in one of two pre-wet modes:
• Pre-set mode (Pre): The quantity of water defined by Pre-wet water is added, regardless of
measured moisture.
• Auto mode (Auto): The sensor moisture reading is used to add water up to the Pre-wet target
using Auto mode control ( - see section Auto mode)
NOTE: When the main Control Mode is set to Pre-set or Calib mode the Hydro-Control V will use Pre-set
mode for the Pre-wet phase of the mix cycle regardless of the Pre-wet mode setting.
Pre-wet delay: The delay between Pre-wet phase completing and continuing the mix cycle. Delays the
Pre-wet done signal, allowing any Pre-wet water to be mixed before cement is added.
First mix time: The duration of the mix that follows the addition of any Pre-wet water and the cement (see
Section Setting Mix Times).
Cement timeout: Maximum time system will wait for CEMENT IN signal before beginning First mix time. If
the system exceeds the maximum permitted waiting time for the CEMENT IN signal, the system will
automatically pause the mix cycle, sound and output ALARM. If no CEMENT IN signal is to be used after a
Pre-wet phase set this parameter to zero.
Moisture target: The moisture value to be reached during the final mix phase.
Preset final: The amount of water to be added during the final wet phase of the mix cycle.
Final mix time: The duration of the mix that follows the addition of the final water (see Section Setting Mix
Times).
Control Mode: The Hydro-Control V can operate in one of three control modes:
• Preset mode (Pre): where the entered amount of water is always added, regardless of measured
moisture.
• Auto mode (Auto): This mode adds a preset amount of water defined by Preset Water during the
‘Pre-Wet’ phase and then uses the sensor moisture readings to control the water addition up to the
Moisture target (see section ‘Auto mode’).
• Calculation mode (Calc): This mode adds a preset amount of water and then calculates the amount
of water to add from a ‘Calculated Moisture Target’ and the ‘Dry Weight’ of the mix. This mode will be
disabled if no value of ‘Dry weight’ has been entered or if there is no water meter present. A Calib
mode mix cycle must be performed in order to calibrate the recipe before this Control mode can be
used (– see section Calc mode).
Plus tolerance: Moisture % above target % at the end of the Final mix time at which the system will sound
and output ALARM. Disabled after mix complete
Recipe Gain: (Used only in Auto mode.) A tuning factor for the control algorithm to provide accurate control
for smaller batch sizes. For a normal batch size this will be 1.0. For reduced batch sizes it will be a number
between 0.0 and 1.0. The Recipe Gain would be set according to the following guidelines:
In the case where an Auto-mode Pre-wet is followed by a Calc mode Final Wet the Recipe Gain can be
increased up to a maximum value of 10.0 to improve the speed of the Pre-wet water addition.
Dry weight: The total dry weight of the mix including all sand, aggregates and cement.
Calib. water: The Preset final parameter defines the amount of water to be added during the final wet
phase of a calibration mix cycle. Setting the Calib. water value to be less than the Preset Final allows the
water to be added in two phases. During the first phase of water addition (when Calib. water litres are
added) the calibration slope will be calculated and during the second phase of water addition (when Preset
final minus Calib. water litres are added) the admix is also added. The Moisture target is then defined with
any required admix present but the calibration slope is not effected.
Water limit: The maximum amount of water that would ever need to be added for this recipe.
Default recipe values may be edited under Setup System - see section Edit System Parameters.
Moisture offset and gain: Factors to convert sensor units into moisture units.
These parameters are used to convert the sensor’s unscaled reading into a displayed moisture value. The
conversion performed is:
With default values the displayed moisture is not intended to be a true indication of the actual value. It is
possible to display actual moisture values by using the results of a ‘bake out’ test to calculate correct
Moisture offset and Moisture gain values.
Since Auto mode and Calc mode use the Moisture gain parameter in calculations changing these
parameters will affect the control. As a result, it may be necessary to recalibrate recipes or change control
parameter.
Typical values will be 0 to -5 for offset & 0.1200 to 3.0000 for the gain. If the parameters are changed, all
other moisture parameters in the recipe will be automatically re-scaled.
Water trim: An amount of water added or removed from the final water of a Calc mode mix cycle.
Cement weight: The weight of cement in the mix. This parameter is only used for calculating the
water/cement ratio which is displayed in the Mix log.
Temperature : The base temperature used for temperature compensation in either degrees Centigrade
(Metric Mode) or degrees Fahrenheit (US Mode).
Temp. Coeff.: The compensation factor used for temperature compensation in % moisture per degrees
temperature (oC or oF). If no compensation is required this should be set to 0.000.
Calibration Type: Determines whether the calibration will be a 1-point or 2-point calibration mix cycle (when
calibrating with admix), refer to page 23/24 for more information.
From the edit recipe page, it is possible to copy complete parameters from one recipe to another. Pressing
<F2> will display the copy recipe page as shown below. Enter the recipe number to be copied in the ‘From’
section using the numeric keypad and press
section and press .
9 . Then enter the destination recipe number in the ‘To’
9
Mix cycle
The current recipe number is displayed in the top box on the right of the screen along with the recipe control
method and the batch number.
The mix run time is displayed in the bottom box on the right of the screen and along the bottom of the trend
graph. Also shown under the run time is a count down of the remaining time in mixing phases of the cycle
(first mix-time or final mix-time).
Throughout the cycle the current moisture value is displayed both in the middle box on the right of the screen
and on the trend graph. Towards the end of the first mix and the final mix times the large % sign flashes.
This is because the sensor is within its averaging time and at this point the moisture trace should be stable.
The middle box on the right of the screen also displays the amount of water to be added during the current
phase of the mix cycle and the moisture target.
The mix cycle phases are displayed in the status bar with the name of each phase of the cycle flashing
between CAPITALS and lowercase to indicate the phase of the cycle reached.
NOTE: If no pre-wet is required the Pre-wet water recipe parameter should be set to zero. This will ensure
that a ‘dry mix cycle’ will be used.
The cycle can be paused at any point by pressing <Pause> (- see section Trim and Update).
Cement timeout
If the system exceeds the maximum permitted waiting time for the CEMENT IN signal, the system will sound
and output ALARM.
<Resume> (F1) Overrides the Cement timeout and resumes the mix cycle.
The maximum permitted waiting time is defined on a per recipe basis by Cement timeout.
Water limit
If Water limit is exceeded the system automatically pauses the mix cycle and the system will sound and
output ALARM.
<Resume> (F1) Overrides the Water limit and resumes the mix cycle.
The maximum amount of water that should be added to a recipe is defined on a per recipe basis by Water
limit.
Plus tolerance
Plus tolerance defines the level above the target moisture at which the moisture of the mix is recognised as
being ‘too high’.
If the moisture at the end of the mix cycle exceeds this level the system will sound and output ALARM.
Disabled after mix complete
Minus tolerance
The Minus tolerance recipe parameter defines the level below the target moisture at which the moisture of
the mix is recognised as being ‘too dry’.
If the moisture at the end of the mix cycle is below this level the system will sound and output ALARM
Disabled after mix complete..
Status bar:
<Abort> (F2): Allows the current mix to be aborted. When pressed the option to generate MIX
COMPLETE signal is prompted with the following “Mix Complete Required?”,
<Yes> (F2) and <No> (F3). If ‘No’ is selected it will return to the Start Menu. If
‘Yes’ is selected the mix complete signal is generated and <Reset> (F2) returns to
the Start Menu and clears the MIX COMPLETE signal.
<Trim> (F3) Opens the FINE WATER valve all the time the key is depressed, allowing manual
adjustment of the moisture level.
Hydro-Control V User Guide 37
HD0193 Issue 2.4.1
Trim and Update
Pressing <Pause> (F2) at any phase in the mix cycle will pause the cycle and any water addition. Messages
showing the current status and at what phase the mix cycle has been paused will be shown, for example.
<Resume> (F1): Continues the cycle from the point where it was paused.
<Abort> (F2): Allows the current mix to be aborted. When pressed the option to generate MIX
COMPLETE signal is prompted with the following “Mix Complete Required?”,
<Yes> (F2) and <No> (F3). If ‘No’ is selected it will return to the Start Menu. If
‘Yes’ is selected the mix complete signal is generated and <Reset> (F2) returns to
the Start Menu and clears the MIX COMPLETE signal.
<Trim> (F3) Opens the FINE WATER valve all the time the key is depressed, allowing manual
adjustment of the moisture level.
<Update> (F5) Followed by 9 saves the adjusted water amounts and moisture levels to the
current recipe.
The availability and function of the <Trim> and <Update> keys depend on the control mode and phase of
the mix cycle as shown in the table below. The shaded cells indicate the phases for which <Trim> is
available and the text indicates which recipe parameters are updated when <Update> is pressed.
The Mix Log contains information on the last 99 mix cycles. On entering the Mix Log the most recent mix
cycles are displayed. Previous mix cycles may be viewed by using the up and down keys
<US> (F1) Displays the sensor readings in unscaled values for the mixes. Repeated key
presses will cycle between displaying % units and unscaled values.
<Water> (F2) Displays the actual water and target water for the mixes.
<Mix> (F3) Displays details of the mixes including total time and the weight.
<Dev> (F2) Displays the sensor readings from the dry and wet phases as in the
sensor readings page, and also the variation of the sensor readings
(deviation) at the end of each phase. They can be in unscaled or
moisture values, depending on which is set in the previous menu.
<Reset> (F4) Clears the Mix Log; confirmation by pressing 9 is required before
the Mix Log is cleared.
The first column in each of the three pages of the Mix Log is an identifier. The identifier consists of the
Batch number, the Recipe number and the mix control mode with the following format:
Dry US/%: The moisture in unscaled or % reached at the end of the First mix time.
Final US/%: The moisture in unscaled or % reached at the end of a mix cycle.
W/C: The water/cement ratio reached at the end of the mix cycle. This parameter will
only be calculated if a cement weight is entered in the recipe. The calculation uses
the dry moisture reading together with the amount of water subsequently added,
therefore the accuracy depends on the calibration of the recipe and the accuracy of
the dry reading.
Pre L: The amount of water added to the mix during the pre-wet phase.
Calc L: The amount of water calculated during a Calc mode mix cycle.
The total amount of water added during the final wet phase(s) of a Calib mode
mix cycle.
For Preset mode and Auto mode mix cycles no value will be shown.
Tot L: The total amount of water added during the mix cycle.
Trim L: The value of the Water trim for a Calc mode mix cycle.
The third page of the Mix Log, accessed by pressing <Mix> (F3), contains the following information:
Dry kg: Dry weight from the recipe of the mix, shown in units selected by Water mode.
The above figure shows the Mix Log with the Water mode set to Metric.
Pressing F2 will show the sensor readings, available in moisture or sensor unscaled values, at the end of the
first mix time and the final mix time, along with the deviation of the signal at the end of these phases.
The deviations can be used as an indication of how stable the signal is at the end of each phase, i.e. how
homogeneous the mix is. The deviation values are calculated by recording the difference between the
maximum and minimum sensor readings over a period of time at the end of the first mix and final mix times –
the averaging time (see control menu parameters). Deviations should therefore be as close to zero as
possible, always less than 3 unscaled units.
Wet dev.
Target
Average ‘Wet’
Dry dev.
Average ‘Dry’
Averaging Averaging
time time
Time
Start Mix Complete
When running in Calc mode, as mentioned, the recipe needs to be calibrated so that the controller will know
the required moisture level. This calibration can be done in two ways.
The first method is to use the Calib mode as described previously on page 28.
The second method is to calibrate the recipe from a previous record in the mix log. As with all calibrations, it
is essential to ensure that the moisture at the end of the first mix and the final mix times are stable, and so
this should be checked before any calibration is carried out. Look at the deviations for both the first and final
mix times. These should be as close to zero as possible, always less than 3 unscaled units.
To calibrate a recipe, select the required recipe that provided a good mix in the mix log. Then press Calib
<F1> from the ‘More’ menu. In order for that mix data to be used for calibration, a number of checks are
performed. These are:
o Water must have been added to the mix. If no water was used then the message “!Calibration failed!
No water added” is shown.
o After the main water is added, the sensor’s unscaled reading must increase by at least 4 units. If the
difference between the unscaled reading in the final mix and first mix are less than 4 units then the
message “!Calibration failed! Low moisture variation” is shown.
o There must be a dry weight in the recipe. If no dry weight is present in the recipe, it is possible to
enter this weight at the beginning of this procedure. The page will change to the following. Enter the
dry weight and press the to accept.
9
The next screen will enable the user to input a theoretical trim on the calibration. This might be useful if the
particular batch in the mix log was a little too wet or too dry. Adding or subtracting a trim here will then adjust
the calibration as if the batch was made with a different quantity of water. For example a batch is made with
30 litres. This is a little too wet by only about 2.5. Therefore using a trim of -2.5 litres would calculate the
calibration as if 27.5 litres was used.
After this, the calibration can be saved and the recipe will be updated with the new parameters.
• Enter the password by typing the correct 4 digits. The words ‘Incorrect’, ‘Correct’ or ‘Advanced’ will
then be displayed to confirm correct entry or warn of incorrect entry.
• If an incorrect password is entered then you must use the <Back> (F5) key to return to the Start
Menu.
• If the standard password has been entered then the <System> (F1) and <Diag> (F2) function keys
will be available.
• If the advanced password has been entered then the <System> (F1), <Diag> (F2), <Control> (F3)
and <Valve> (F4) function keys will be available.
Water mode: Determines how the water is measured into the mixer. If you have no water meter use ‘Timed’,
otherwise select ‘US’ (US Gallons, lbs and degrees Fahrenheit) or ‘Metric’ (litres, kg and degrees
Centigrade) to match your system.
Meter flow/pulse: The quantity of water measured by each pulse of the water meter
Meter timeout: If no water pulses are received within this time after opening the valve then an alarm is
generated and the system will pause.
<Reset> (F1): Resets the water added and the time elapsed shown in the display
box to zero.
<Fine> (F2): Activates the FINE WATER output all the time the key is depressed
and will stop when the key is released. The amount of water added
and the time elapsed are shown in the display box.
<Coarse> (F4): Activates the COARSE WATER output all the time the key is
depressed and will stop when the key is released. The amount of
water added and the time elapsed are shown in the display box.
<Keys> F4: Shows a mimic of the keypad and displays keys pressed
NOTE: INCORRECT VALUES MAY STOP THE SYSTEM FROM WORKING PROPERLY. CHANGES
SHOULD ONLY BE MADE BY COMPETENT OPERATORS.
The control algorithm used in Auto mode attempts to make a compromise between achieving the moisture
target as quickly as possible and on the other hand, not letting the moisture level overshoot the target level.
The factors that affect this compromise include:
Adjusting the various control parameters permits optimisation to suit local conditions. The Hydro-Control V
has been designed and configured so that most users will never need to know the details of the control
method used and will not need to change the settings. However if your mixer system is unusually fast or slow
in its response, and you are familiar with system control methods and theory, you might be able to optimise
your system response time by adjusting the default parameters.
Gain; Upper Control Threshold; Lower Control Threshold; Valve on/off Time:
Fine delivery: When a fixed amount of water is being added to a mix the last ‘fine delivery’ litres of the water
will be added using the fine valve only.
NOTE: Setting this parameter to be greater than 99 will ensure that only the fine valve is used for any mix
cycle.
In-flight: The amount of water that continues to flow into the mixer after the valve output has been switched
off. Calc mode mix cycles require this value to be set correctly in order for calculations to be performed
accurately.
Averaging time: During the mix phases of any mode mix cycle the system will average the moisture values
over this period of time.
Mix extension: During a calibration run, the system will extend the final mix time by the Mix extension time
to ensure that a good final reading is obtained.
Access mode: When set to Lock, prevents editing of recipe parameters and allows user to change only
between the current mix cycle mode and Preset mode (In the case that signal is lost from the sensor it is still
possible to run the recipe in preset mode).
Valve – Pre-wet: Selects the valve used during Pre-wet phase. Can be set to Both (default setting), Fine
only or Course only.
Valve – Final-wet: Selects the valve used during Final-wet phase. Can be set to Both (default setting),
Fine only or Course only.
Note: When using only one valve for water input, it is always recommended to connect to the ‘Fine Valve’
output. In such cases it is not necessary to change the above valve parameters to ‘Fine’ as the default
setting of ‘Both’ will always work.
Figure 28 – Diagnostics
The Diagnostics screens are only used for troubleshooting and will normally only be accessed after
instruction from Hydronix.
• To read system information and test the Current Interface press <H/W> (F1)
Figure 29 – Hardware
To test the sensor analogue output, select ‘Test’ <F3>. This will force the current to the indicated value. Use
the numeric keypad or the <Inc> (F1) and <Dec> (F2) keys to vary the current between 0 – 20mA.
NOTE: The current interface is not normally used when connected to a Hydro-Control V.
The ‘Calib’ function shown above in <F4> only appears when a Hydro-Probe Orbiter is connected. This is
used to perform an Autocal which is used when a new sensing arm is connected to the sensor.
Figure 30 – Resonator
• To view the Raw readings with a 2 second time-base press the <Raw2> (F1) key.
• To view the Raw readings with a 100 second time-base press the <Raw100> (F2) key.
• To view the Filtered readings with a 2 second time-base press the <Fil2> (F3) key.
• To view the Filtered readings with a 100 second time-base press the <Fil100> (F4) key.
These should not be changed after commissioning as this could adversely affect system
performance.
To change a parameter, move the cursor (<) to the parameter required using the up and down
keys:
Type the desired value using the numerical keypad or use the <Inc> (F1) and <Dec> (F2) keys to increment
or decrement the value.
The ‘Calib’ function shown above in <F4> only appears when a Hydro-Probe Orbiter is connected. This is
used to perform an Autocal which is used when a new sensing arm is connected to the sensor.
After completion of editing press <Back> (F5) and then either of the following keys:
Output type: Sets the analogue output characteristics of the sensor to the required type. Not used by the
Hydro-Control V but available from sensor.
Output variable: Determines which variable is available on the sensor analogue output:
• Filtered - Unscaled reading filtered using the sensor filtering time and slew rates.
• Raw – Unscaled reading with no filtering applied.
I/P 2: This parameter is not relevant to Hydro-Control V and will always be set to ‘None’.
Filtering time: Determines the filtering time in a sliding window averaging process..
Slew rate + & Slew rate - : These parameters are used by the sensor to limit the effect of rapid transient
signals due to mixer blades or noise spikes on the electrical supply lines. They set, respectively, the
maximum positive and negative voltage change allowed between successive sensor readings.
The Hydro-Control V can be connected to a remote device such as a programmable logic controller (PLC) for
remote recipe selection or a batch control computer for remote recipe selection and reading of various
parameters for logging purposes.
Note: All commands are terminated with a ‘Carriage Return’ code, ASCII 13.
Also note that the position of spaces between command characters is important. In the next
sections, the character ”_” represents a space and must be used where shown
To prevent accidental changes that may produce undesirable effects, some commands are only valid during
certain parts of the cycle. These are shown below.
For example:
• Changing the active recipe can only be done when the Hydro-Control V is in standby phase (since
changing a recipe in the middle of an active mix phase will probably produce an erroneous mix).
Response will be ‘Not While Active’ if attempted during any other phase.
• ‘Mix complete at’ is only meaningful during the mix complete phase; the parameter will return zero at
all other phases.
NOTE: During operation, ‘noise’ on the RS232 connection may be interpreted as characters by the Hydro-
Control V. Sending a ‘Carriage Return’ code, ASCII 13, will clear the input buffer, and generate a ?10
response. The Hydro-Control V will now be ready for receiving valid remote commands.
• Send the ASCII string: >R1=10 Do not forget the ASCII 13 terminator.
• Note there are no spaces in this command.
e.g. if the current moisture is 5.61% then the response to *2 will be 5.61
If the final moisture target achieved is required for record purposes then Mixer Status command should be
used, see later in this chapter.
e.g. If the current temperature is 25.0 then the response to *5 will be 25.0 C.
e.g. if the unscaled reading is 35.61 then the response to *7 will be 35.61
To read the value of recipe parameter pp in recipe no. nn send a message in the form:
For example, if the final water target (parameter 7) of recipe 5 was 8.5%:
• Send the ASCII string: #_R_5_7 (Do not forget to terminate with ASCII 13, ‘carriage return’.)
• Receive: 85
Recipe parameters can be read by specifying the recipe number (1-99) and the parameter number (see table
below).
All the major recipe parameters can be written over the RS232 link. The format and parameter list are similar
to the read command, i.e. to write the value of recipe parameter pp in recipe no. nn send a message in the
form:
For example, to set the final water target (parameter 7) of recipe 5 to 8.5%:
• Send the ASCII string: #_W_5_7_85
• Do not forget to terminate with ASCII 13, ‘carriage return’.
System parameters can be read by specifying a ‘recipe’ number of 0 and the parameter number (101-131,
see table below).
Seconds, Litres or
107 Pre-wet water 150 15.0
US Gallons
108 First mix time Seconds 10 10
109 Cement timeout 1 sec 5 5
110 Moisture target 0.1 % 65 6.5
Seconds, Litres or
111 Preset final 350 35.0
US Gallons
112 Final mix time Seconds 15 15
All major system parameters can be written over the RS232 link. The format and parameter list are similar to
the read command, i.e. to write a value vv to system parameter pp send a message in the form:
12 Total water added (at Mix Complete) Litres or US Gallons 82.20 82.20
24 Time taken to reach Mix complete (at Seconds 140 140
Mix Complete)
If system is not in MIX COMPLETE phase, dependent values returned will be 0.00.
The Status byte returns an indication of the current phase of the mix cycle:
NOTE: For example if the system is paused in the wet mix phase, the command #_M_0_25 will return 160
since the status value is: 32 (Wet Mix) + 128 (Paused) = 160 (Total)
Code Meaning
Value The data requested from a valid command. Value may be
in integer, floating point or string format.
The Hydro-Control V replies to all invalid commands with one of the following responses:
Value Meaning
?10 Invalid command
?11 Parameter 1 out of range
?12 Parameter 2 out of range
?13 Parameter 3 out of range
?14 Command not valid while mix active
All replies are terminated with a carriage return (ASCII code 13).
Connecting to a PC/Laptop
The upgrade utility uses the Hydro-Control V RS232 serial connections and you will need the appropriate
connecting cable as described below.
Connect the COM port of the PC/Laptop to the RS232 connections on the Hydro-Control V using the
following diagram:
21 RxD 3 TxD
22 TxD 2 RxD
23 Gnd 5 Gnd
Hydro-Control V PC/Laptop
9 pin DIN
Any new software versions and the utility to upgrade the Hydro-Control V are available on the Hydronix web
site http://www.hydronix.com/
Note that when upgrading, the system parameters, control parameters and recipe data will return to their
default value. The upgrade utility therefore has a backup and restore feature which will allow the parameters
to be downloaded onto the computer, then uploaded again so that the Hydro-Control V will once more be
fully functional.
• With the 9 key depressed, switch on the Hydro-Control V. This will place the unit into upgrade
mode.
Warning: Whilst performing upgrade – please ensure the power is stable for the
complete duration. The upgrade takes approximately 10 minutes. If a problem
with the power supply occurs at the end of this procedure it could cause the
Hydro-Control V to become inoperable and in such a situation would need to be
repaired by Hydronix.
This chapter describes how to install the Hydro-Control V, including connection of the Hydronix moisture
sensor and the RS485/RS232 communications link.
Safety Instructions
The Hydro-Control V has been designed in accordance with the recommendations of IEC 664 and has been
supplied in safe condition.
If the equipment is used in a manner not specified by the manufacturer the protection
provided by the equipment might be impaired.
Precautions
Disconnect from voltage supply before the unit is opened for any adjustment, maintenance or repair work.
Ensure that only fuses of the correct type and rating are fitted.
Ensure that the Hydro-Control V is mounted in an environment that will not cause electrical interference.
Ventilation Requirements
It is important to ensure that the Hydro-Control V has adequate ventilation and that the side vents are not
restricted.
Many installations will be in situations that are particularly prone to damage by lightning, for example:
• Tropical Regions.
• Outdoor installations.
• Long cable runs between the sensor and the control panel.
• Tall, electrically conductive constructions (e.g. aggregate bins).
Although the Hydro-Control V is fitted with Opto-Isolation on the sensor input, this will not prevent damage in
all cases. Precautions should still be taken to avoid damage by lightning in areas where there is a known
risk.
We would recommend the installation of suitable lightning barriers to all conductors in the sensor extension
cable. Ideally, these would be fitted at both ends of this cable to protect both the sensor and the Hydro-
Control V plus any other equipment connected to it.
• Cut out an aperture in the panel: 178 mm High x 232 mm Wide (7.01 in x 9.13 in)
• Remove the pair of mounting brackets from the Hydro-Control V by releasing the screws and
unhooking the brackets from the body of the unit.
• Insert the Hydro-Control V through the prepared hole.
• Re-fit the mounting brackets to the unit and tighten the screws to pull the fascia towards the control
panel. Do not over-tighten as this may distort the fascia plate.
Wiring Connections
The wiring connections for the Hydro-Control V are shown in Figures 36, 37 & 38.
The sensor must be connected using an extension cable made up from a suitable length of two pairs twisted
(4 cores total) screened (shielded) cable with 22 AWG, 0.35mm2 conductors. It is recommended that a high
quality cable with good braid screen and also a foil screen is used in order to minimise the possibility of
interference. Recommended cable types are Belden 8302 or Alpha 6373. The cable screen must be
connected at the sensor end only, and therefore it is essential that the sensor body has a good connection to
an electrical earth.
The cable run from the sensor to the control unit must be separate from any heavy equipment power cables,
particularly the power cable for the mixer. Failure to separate the cable runs can lead to signal interference.
Final Mix
Final Wet Discharge
Add
Cement
Pre Wet
Mixer
Loading First Mix
Time
Inputs
Start
Water Meter
(Optional)
Cement In
Reset
Outputs
Coarse Water
Fine Water
Pre-Wet Done
Mix Complete
Status
st
Start Pre Wet CEM 1 Final Wet Wet Mix Mix Complete Start
Menu Mix Menu
First Mix
Time
Mixer
Loading
Inputs
Start
Water Meter
(Optional)
Cement In
Reset
Outputs
Coarse Water
Fine Water
Mix Complete
Status
st
Start 1 Mix Final Wet Wet Mix Mix Complete Start
Menu Menu
Add
Cement
Time
Busy mode
Water
Admix
All
Water
Admix
All
START MENU
System is waiting for START signal. The mixer will normally be running, and the aggregates will often be
loaded or discharged with the Hydro-Control V at the Start Menu.
Following the addition of aggregates, a START input (either by pressing the front panel button or by the plant
computer sending the input high) will cause the system to add the amount of water defined in the recipe to
the mixer before the cement is added. The mix cycle will continue after the time defined by the pre-wet
delay. If no pre-wet is required the Pre-wet water and Pre-wet target should be set to zero. This will ensure
that a ‘dry mix cycle’ will be completed.
System will output a PRE-WET DONE signal indicating the Pre-wet is complete. This signal can be used to
initiate the addition of cement. This phase terminates when either the CEMENT IN input is received, or the
system exceeds the maximum permitted waiting time for the CEMENT IN signal. To avoid ambiguity, the
CEMENT IN signal may stay high until the Hydro-Control V issues a MIX COMPLETE.
FIRST MIX
Time allowed for aggregates and cement to blend before entering controlled water addition. This is defined in
the recipe menu.
FINAL WET
Time during which the system will control the water addition to achieve the target moisture value.
FINAL MIX
Time allowed for mix to achieve a homogeneous state following all water addition.
MIX COMPLETE
If at the end of the wet mix, the Hydro-Control V outputs a MIX COMPLETE signal, which may be used to
initiate a discharge sequence.
START MENU
After the RESET input (either by pressing the front panel button or by the plant computer sending the input
high) the MIX COMPLETE signal is cancelled and the system goes back to the Start Menu. The mix cycle
will start as soon as another START input is received.
Inputs
START/RESUME
Minimum 200mS pulse used to initiate the next mix cycle or to resume current mix cycle following a pause.
Event occurs on leading edge of pulse.
CEMENT IN
Minimum 200mS pulse to indicate that cement addition to the mixer is complete. Event occurs on leading
edge of pulse.
PAUSE/RESET
Minimum 200mS pulse used to place the unit in a ready state for the next batch and remove the MIX
COMPLETE signal. Can also be used to pause the current mix cycle. Event occurs on leading edge of pulse.
WATER METER
Maximum 50 Hz input used for counting the amount of water added. Water mode, Meter flow/pulse and
Meter timeout are used for setting up the water meter input. Count occurs on leading edge of pulse.
Outputs
COARSE WATER
Output used to switch on the coarse valve. Maintained high while coarse water required.
FINE WATER
Output used to switch on the fine valve. Maintained high while fine water required.
BUSY
Output used to signal that the system is busy, either (i) during only the Pre-wet and Final wet phases of the
mix cycle, (ii) during the final water addition phase only (for use with admix) or (iii) throughout the whole mix
sequence, selectable by Busy mode (see System Settings).
PREWET DONE
Output used to signal that the Pre-wet phase (Pre-wet water addition and Pre-wet delay) has completed.
Maintained high until CEMENT IN received. If Cement timeout is set to zero then this pulse will be
momentary.
MIX COMPLETE
Output to indicate that the unit has completed the current batch mix cycle. Maintained high until RESET input
received.
ALARM
Output to indicate that the unit has entered an ALARM condition. Intervention is normally required to clear
the alarm.
ALARM!
No response
from sensor nn
After a maximum of 15 seconds the display sensor should be located and the display will change to the
standard Start Menu (– see section Start Menu), displaying the current moisture value and the trend
display.
1. Press <More…> (F5) and then <Setup> (F1) to access the Setup System menu.
2. Enter the Advanced password (see Appendix D), press <Diag> (F2) followed by <Mon> (F3) to
display the Monitor page that shows the unscaled values being read from the sensor.
3. With the mixer empty and the sensor clean and dry, the unscaled value shown should read close to
zero (0). Due to differences in installation the empty value may vary and acceptable values will be in
the range 0 to 14.
4. Get someone to place the palm of their hand on the sensor; the unscaled value should now climb to
a value of 70 - 85 over a period of approximately 30 seconds. The value does not reach the final
value instantly due to the rate limiting and smoothing filters in the sensor.
The above verifies that the sensor is working correctly and that the communications with the sensor is also
working correctly.
6. Press <Fine> (F2) and keep pressed to ensure the fine valve activates correctly.
7. Press <Reset> (F1) to reset the display and repeat using <Coarse> (F4) to check the coarse valve.
The system parameters Water mode, Meter flow/pulse and Meter timeout must be correctly set before
performing any meter testing – see section Edit System Parameters.
Arrange for the water delivered from both the coarse and fine valves to be diverted into a suitable container
so that the actual amount of water delivered can be determined.
5. Enter a time in First mix time that will allow you to reach the water delivery point.
6. Check the Water limit parameter on page two of the recipe is greater than the Preset Final
10. Press <Start> (F1), to start the dummy recipe; you will now have the amount of time defined by the
First mix time to reach the area where the water is delivered to check the delivery.
11. After the water turns off, check the water amount shown on the display is consistent with the amount
of water delivered.
The amount of water delivered and shown on the display ideally should be exactly the same as that
requested by the Preset Final parameter. In most installations this will not be the case, as some water will
continue to flow after the valves have been switched off. The Fine Delivery and In-flight parameters can
now be adjusted to optimise the accuracy of the delivery – see section Edit Control Parameters.
After the water meter has been calibrated the flow rate of the fine and coarse valves may be checked from
the Checking valves menu by pressing <Fine> (F2) or <Coarse> (F4) and dividing the amount of water
displayed by the amount of seconds displayed. See Chapter Valves and Water Flow Rates for guidelines.
START / RESUME
PAUSE / RESET
MIX COMPLETE
PREWET DONE
CEMENT IN
ALARM
Binary BCD Discret
BUSY
5 6 7 8 9 10 11 12 13 14 15 16 17 18 27 29
24 25 26 28
Remote 24VDC Hydro-Mix
21 22 23
(OR)
1 2 3 4 19 20
External
24V DC 30 N/C
29 0V
BLK B 28 SENSOR 0V
Hydro-Mix V 27 +24V DC
Sensor A
RED 26 SENSOR +24V DC
MIL-Spec
Connector BLK G 25 RS485B
WHT F 24 RS485A
RS232 23 RS232 GND
Serial 22 RS232 TX
Link
21 RS232 RX
20 WATER METER -
19 WATER METER +
18 PAUSE/RESET -
External 17 PAUSE/RESET +
Inputs
16 START/RESUME -
15 START/RESUME +
14 CEMENT/MIX LOADED -
13 CEMENT/MIX LOADED +
12 BUSY -
11 BUSY +
10 ALARM -
Status 9 ALARM +
Indicator
Outputs 8 MIX COMPLETE -
7 MIX COMPLETE +
6 PRE-WET COMPLETE -
5 PRE-WET COMPLETE +
4 FINE WATER -
Water
Valve 3 FINE WATER +
Control 2 COARSE WATER -
1 COARSE WATER +
Note: The sensor cable screen is connected on Pin H of the Mil Spec connector ONLY.
27 29
26 28
+24 V Hydro-Mix
V/VI
0V
Hydro-Control V or
RS485
24 25
Hydro-Probe
Orbiter
+ _
+ _ + _
19 20 3 4 1 2
_ _ Fine Coarse
Valve * Valve
O/P Water I/P
Meter External
+ + _ Power Supply
+
Relay or Volt Free Output
Water Meter
Cut-out for
Operator
Terminal
190mm
78mm 246mm
6mm
• BCD: The recipe number is applied in Binary Coded Decimal form. This allows all
recipes 1 through 99 to be selected using eight inputs.
• BINARY: The recipe number is applied in Binary form. This allows all recipes 1 through
99 to be selected using seven inputs.
• DISCRETE: Each input allows one recipe to be selected, allowing recipes 1 through 10 to
be used.
The selection method is configured by the state of inputs A and B on the PLC as defined in the table
below:
Note: There has to be a recipe in the Hydro-Control V to be able to select it. If there is no recipe, the
selection remains as the last one selected.
21 RxD 7 TxD
22 TxD 4 RxD
23 Gnd 5 Gnd
Hydro-Control V PLC
The PLC software is programmed to send a Recipe Select command via the RS232 port after the
input selection is made: the input selection must change from zero to the desired selection code
(according to the coding method as above: BCD, Binary or Discrete) for more than 200ms, then return
to the Zero state.
Additionally, the PLC will operate relay output P47 after a Recipe Select command – the Hydro-
Control V requires that Recipe Selection is made during Start menu only, this output may be used to
delay the START signal to the Hydro-Control V in case the Recipe Selection is made at the same
instant as the plant Start signal in order to ensure the selection is registered.
The relay output P47 may also be used to originate a START signal upon receipt of a Select Recipe
command. For example, different remote plant stations may invoke a START signal simply by sending
a Recipe Select, which may be unique to each station. The batching plant must still load the mixer, of
course.
Mode switch
Coding
selection
link
RUN
PAU/REM
STOP
P00 P02 P04 P06 P08 P0A COM0
P01 P03 P05 P07 P09 P0B 24G 24V
9 6
Hydro-Control V
START input
15
Plant
Start output
16
Hydro-Control V
START input
15
16
Hydro-Control V
START input
While the Hydro-Control V can work with a single water control valve, optimum performance (fastest
cycle times with least overshoot) will probably only be achieved with:
It is essential that the valves are correctly sized and flow rates correctly adjusted with respect
to the mixer capacity and efficiency.
Valves should be able to turn on and off rapidly – the combined on/off cycle time for a 50 mm (2”)
valve should be no more than 2 seconds and 19 mm (3/4”) valves should have combined on/off cycle
time of no more than 1 second. This permits precise water addition.
Example:
Metric units:
If a 1m3 mixer has only a coarse valve with a water flow rate through the valve is 10 L/s and an on/off
cycle time of 1 sec, then water can only be added in 10 L steps. With a full load (~ 2200 Kg) then the
smallest moisture step is approx. 0.5%, which is too coarse for adequate control.
If the same system was also fitted with a fine valve which had a flow rate of 1 L/sec and an on/off time
of 1 sec, then using this valve would permit water addition in steps of approx. 1 L or 0.05% giving good
control.
US units:
If a 35ft3 mixer has only a coarse valve with a water flow rate through the valve is 3 Gal/s and an on/off
cycle time of 1 sec, then water can only be added in 3 Gal steps. With a full load (~ 4800 lbs) then the
smallest moisture step is approx. 0.5%, which is too coarse for adequate control.
If the same system was also fitted with a fine valve, which had a flow rate of 0.3Gal/sec and an on/off
time of 1 sec, then using this valve would permit water addition in steps of approx. 0.3Gal or 0.05%
giving good control.
It is worth noting that a higher water flow rate should normally allow a shorter mix cycle time for an
efficient mixer, provided the valve is fast enough to control the dose (on/off time is short). A slow flow
rate and slow valve will provide the same dosing accuracy but will take longer to complete a mix.
• Fine valve flow rate multiplied by on/off cycle time should be in the range 0.04% to 0.1%
moisture increase (e.g. into 1m3 {35ft3} mixer, flow rate x on/off time should be in the range 1 to
2.4L {0.26 to 0.63Gal})
• Coarse valve flow rate multiplied by on/off cycle time should be in the range 0.25% to 0.5%
moisture increase (e.g. into 1m3 {35ft3} mixer, flow rate x on/off time should be in the range 6 to
12L {1.6 to 3.2Gal}))
• Valve on/off time if in doubt, set it to one second, then choose valve sizes to give suitable flow
rate according to the chart below
• Valve Cycle Time should be at least twice the Valve On/Off Time, with a minimum cycle time
of 3 seconds recommended.
Supply Voltage
24V DC 11W nominal power for Hydro-Control V and sensor
Recommended supply 24 V DC, 1A minimum (24W).
Important: If using 24V DC for inputs/outputs (valves etc), use a separate 24V DC supply to
that powering the Hydro-Control V.
NOTE: The power cable must be screened and the screen connected at the earth stud on the
Operator Terminal only.
Keyboard
Sheet keyboard with polyester overlay.
Graphical Display
120 mm x 90 mm (4.75” x 3.55”) ¼ VGA display with backlight
Security
Open access for operators. Critical operations protected by two levels of pass codes
(supervisor & engineer level).
Connections
Sensor cable
Two pairs twisted (4 cores total) screened (shielded) cable with 22 AWG, 0.35mm2
conductors.
Maximum cable run: 100m, separate to any heavy equipment power cables.
Interface Modules
Six output modules and four input modules are provided as standard.
For voltage options refer to Installation.
At least the FINE WATER output must be connected. All other connections are optional and
can be connected as appropriate for each configuration.
Electromagnetic Compatibility
Meets the requirements of Electromagnetic Compatibility Directive 89/336/EEC
Mechanical
Dimensions
Fascia: 190 mm (H) x 246 mm (W); (7.48” (H) x 9.69” (W))
Panel Cut out: 178 mm (H) x 232 mm (W); (7.00” (H) x 9.14” (W))
Max Panel Thickness: 12 mm
Depth: 84 mm (3.54”)
Depth behind Fascia: 78 mm (3.31”)
Weight: 2.15 Kg (4.75 lb)
The Advanced Control Parameters are only used by the Auto mode mix cycle control.
To access the Advanced Control Parameters the ‘Hydronix’ password must be entered at the
System Setup menu (see section Setup System). Enter the edit system control parameters menu by
pressing <Control> (F3) and move the cursor (<) down to ‘More…’ at the bottom of the menu.
Coarse/upper threshold ratio - together with the Upper control threshold, this ratio defines the
point at what the coarse valve is no longer used. A lower value will keep the COARSE WATER output
on for longer, switching the FINE WATER output on closer to the Moisture target.
Derivative/gain - together with the Gain, this ratio defines the Derivative gain: This value attempts to
compensate for how fast the moisture content is rising, and slows the water addition if the moisture
content is rising rapidly.
Cycle/on-off – together with the Valve on/off time this ratio defines the Valve cycle time: This
determines how often the valves are switched on and off. It should not be less than twice the On/Off
time. A shorter time will be faster and give more precise control (if your mixer is fast enough to take
advantage of it) but will cycle the valves more often, which could lead to wear.
Samples: The number of seconds over which the readings from the sensor will be averaged to
provide the moisture reading. The Hydro-Control V reads the moisture from the sensor 5 times per
second during mix cycles.
Cycle Loops: Sets the number of times the Hydro-Control V will loop through the final-wet and final
mix phases of the mix cycle. This is useful when performing linearity tests, where the same amount of
water needs to be added in steps. As an example, if a linearity test is to be performed and the water is
added in 5 stages, then the complete cycle would be (with no prewet):
Cycle Loops = 5
First Mix > Final Wet 1> Final Mix 1> Final Wet 2> Final Mix 2> Final Wet 3> Final Mix 3>
Final Wet 4> Final Mix 4> Final Wet 5> Final Mix 5
Address: Allows sensor selection when more than one sensor is connected via RS485. Setting this to
zero enables the Hydro-Control V to communicate with all address numbers (1-16) whereas a non-
zero number will make the Hydro-Control V only communicate with that specific sensor.
Auto mode
The Auto mode control algorithm the Hydro-Control V used in the final wet phase of the mix cycle is
a modified Proportional/Differential (PD) algorithm. In these types of algorithm, the system first
calculates the difference between the current value of moisture and the target value. This difference is
used in two stages to define an output level, which can be considered as the percentage of time the
water valves are open.
First, the difference is multiplied by the proportional gain. In this way as the current moisture value
approaches the Moisture target, the output drops and the likelihood of over-shooting the target is
reduced. A value of 20-40 is typical for moderate to good mixers. Slower acting mixers should use
lower values.
Secondly the rate of increase or decrease of the difference is calculated. This is multiplied by the
derivative gain and subtracted from the output level. This parameter makes a correction for how
quickly the moisture level is rising, again in an attempt to prevent overshooting the target.
The overall output level is calculated and constrained to be a number between 0 and 100, with large
numbers representing the valve(s) being on for a greater percentage of time and zero meaning the
valve is off. In systems with both a coarse and a fine valve, if the output level is greater than a certain
value (determined by Coarse/upper thr. in the Advanced Control Parameters) then water is added
using both the coarse and the fine valves. If the output level is below this level only the fine valve is
used.
Calc mode
Calc mode calculates the amount of water required to achieve a moisture target. In this way the user
still achieves an accurate Moisture target but the water required is added in ‘one shot’ to the mixer.
Each recipe must first be calibrated (see Section Calc Mode). During a calibration mix cycle a fixed
amount of water (the Calib. water for that recipe) is added to a mix during the Final wet phase. The
system uses the Dry weight of the mix and the ‘dry’ and ‘wet’ values of moisture (the moisture at the
end of the First mix and Final mix respectively) to calculate a calibration slope for that recipe (relating
the change in moisture of the mix to the amount of water added). It is important to note that if additives
are to be added to the mix these must be added after the calibration slope has been calculated. (To
facilitate this water can be added to a calibration run in two stages - see Section Calc Mode). At the
end of the mix two moisture targets are automatically defined for the recipe – the Calc % and
Moisture target. The Calc % target is defined by the final moisture level generated by the water
addition only and not by the effects of any mix additives. The Calc % target is used to calculate the
amount of water to be added to each subsequent Calc mode mix cycle. The Moisture target is the
final value of moisture reached at the end of the calibration run taking into account the moisture level
generated by the water addition and any modifications to the moisture level generated by the addition
of mix additives.
At the end of a calibration run the user will be prompted to enter a ‘final target’ value. This value will
allow the displayed final target moisture to be defined. For example, after a calibration run the final
target moisture reading might be 6.3%. If the user would prefer the final reading to be 8.0% then 8.0
should be entered when prompted. The calculated and final target moisture targets for that recipe
will then be automatically amended without altering the calibration.
System parameters
This section should be used to record the System setup parameters.
Parameter Value
Water mode
Meter flow/pulse
Meter timeout
Language
Busy Mode
Max. recipes
Control parameters
This section should be used to record the System Control setup parameters.
Standard Advanced
Operator password
Operators do not need a password.
Operators can:
Supervisor password
Supervisors can:
The passwords are printed separately on the next page and can be removed to protect system
security.
Hydronix password
The Hydronix password (used to access the advanced control parameters) is 0336.
NOTE: You may wish to remove this page from the book to prevent unauthorised use of these
passwords.
The speed with which any water control system can work is very much dependent on the time taken to
obtain a meaningful reading. The moisture reading from the sensor indicates what is happening in the
mixer. The speed of reading, or the time taken to reach a steady reading when the materials are
homogenous reflects the effectiveness of the mixer. By taking some simple precautions, the overall
performance can be considerably improved and the cycle time reduced with consequent financial
savings.
Ensure the mixer blades are regularly adjusted to comply with the manufacturers
recommendations (normally 2mm clear of the floor), with the consequent benefits:
• Mixing action close to the floor of the mixer is improved, thereby improving the reading
of the sensor.
It is recommended that the blade or blades sweeping across the sensor face should be of
the plastic synthetic type as this helps to keep the sensor clean and can sweep closer to
the sensor with less risk of damage.
3. Cement addition
Mixing the fine cement particles in with the relatively coarse particular size of the sand and
aggregates is a tough job. When possible, the cement addition should commence within
a few seconds after the commencement of the addition of the sand and aggregates.
Folding in the materials together in this way will greatly assist the mixing process.
4. Water addition
To facilitate the mixing action, the water should be sprayed in over as wide an area as
possible, rather than discharged at one point. Remember excessively rapid water addition
will increase the wet mix time required to reach homogeneity. Hence there is an optimum
rate of water addition for achieving minimum mix cycle time.
Commencement of water addition should only start after the cement has been
substantially mixed in with the aggregates.*
*Cement powder lying on the surface of the aggregates will absorb the water turning into a wet paste, which will
be more difficult to disperse uniformly throughout the mix.
If for any reason the Diagnostics utility cannot be used, please record the parameters and
other details as indicated below. It is important that you have this information ready to fax
when you are speaking to our Customer Support Staff.
UNIT SERIAL NUMBER (as found on the back plate of the Hydro-Control V)
PLANT PARAMETERS
Pre-wet water
First Mix Time
Final Moisture %
Final Mix Time
SYSTEM PARAMETERS
Water mode
Meter flow/pulse
Meter timeout
Setup password
Language
Busy Mode
Max. recipes
Gain
Upper Control Threshold
Lower Control Threshold
Valve on/off Time
Fine delivery
In-flight
Averaging Time
Mix Extension
Access mode
Valve – Pre-wet
Valve – Final-wet
System Mode
Coarse/upper thr.
Derivative/gain
Cycle/on-off
RS232 Mode
Samples
Cycle Loops
Address